Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Journal of Sound and Vibration

Volumn 317, Issue 3-5, 2008, Pages 664-686

  Sims, N D ^a   Mann, B ^b   Huyanan, S ^a  

^a UNIVERSITY OF SHEFFIELD   (United Kingdom)

^b Duke University   (United States)

Author keywords

[No Author keywords available]

Indexed keywords

CODES (SYMBOLS); FINITE ELEMENT METHOD; FORECASTING; MACHINING; MILLING (MACHINING); TIME DOMAIN ANALYSIS;

ANALYTICAL PREDICTIONS; CHATTER STABILITY; CUTTING FORCE COEFFICIENTS; DISCRETISATION; FINITE ELEMENT (FE) FORMULATION; HELIX ANGLES; MACHINING PROCESSES; MILLING TOOLS; MODEL PREDICTIONS; RADIAL IMMERSION; REGENERATIVE CHATTERS; SELF-EXCITED VIBRATIONS; SOLUTION PROCESSING; SURFACE FINISHING; TIME DOMAIN (OCT); TIME-AVERAGED; TOOL WEARS; VARIABLE PITCH;

SYSTEM STABILITY;

EID: 48349138966     PISSN: 0022460X     EISSN: 10958568     Source Type: Journal    
DOI: 10.1016/j.jsv.2008.03.045     Document Type: Article

References (35)

1. Tlusty J. Manufacturing Process and Equipment. first ed. (2000), Prentice-Hall, Englewood Cliffs, NJ
2. Wiercigroch M., and Budak E. Sources of nonlinearities, chatter generation and suppression in metal cutting. Philosophical Transactions of the Royal Society of London, Part A 359 (2001) 663-693
3. Tlusty J. Dynamics of high-speed milling. Journal of Engineering for Industry 108 (1986) 59-67
4. Altintas Y., and Budak E. Analytical prediction of stability lobes in milling. CIRP Annals 44 (1995) 357-362
5. Tarng Y.S., Kao J.Y., and Lee E.C. Chatter suppression in turning operations with a tuned vibration absorber. Journal of Materials Processing Technology 105 (2000) 55-60
6. N.D. Sims, A. Amarasinghe, K. Ridgway, Particle dampers for workpiece chatter mitigation, Presented at the 2005 ASME International Mechanical Engineering Congress and Exposition, November 5-11, 2005, Orlando, FL, USA, 2005.
7. Segalman D.J., and Redmond J.M. Chatter suppression through variable impedance and smart fluids. Proceedings of SPIE-the International Society for Optical Engineering 2721 (1996) 353-363
8. Wang M., and Fei R. Chatter suppression based on nonlinear vibration characteristic of electrorheological fluids. International Journal of Machine Tools and Manufacture 39 (1999) 1925-1934
9. Wang M., and Fei R. Improvement of machining stability using a tunable-stiffness boring bar containing an electrorheological fluid. Smart Materials and Structures (1999) 511-514
10. Dohner J.L., Lauffer J.P., Hinnerichs T.D., Shankar N., Regelbrugge M., Kwan C.-M., Xu R., Winterbauer B., and Bridger K. Mitigation of chatter instabilities in milling by active structural control. Journal of Sound and Vibration 269 (2004) 197-211
11. N.D. Sims, Y. Zhang, Piezoelectric active control for workpiece chatter reduction during Milling, Presented at the Smart Structures and Materials 2004, Smart Structures and Integrated Systems, 2004.
12. Pratt J.R., and Nayfeh A.H. Chatter control and stability analysis of a cantilever boring bar under regenerative cutting conditions. Philosophical Transactions of the Royal Society of London, Part A 359 (2001) 759-792
13. Al-Regib E., Ni J., and Lee S.-H. Programming spindle speed variation for machine tool chatter suppression. International Journal of Machine Tools and Manufacture 43 (2003) 1229-1240
14. Altintas Y., and Chan P.K. In-process detection and suppression of chatter in milling. International Journal of Machine Tools and Manufacture 32 (1992) 329-347
15. Altintas Y., Engin S., and Budak E. Analytical prediction of chatter stability and design for variable pitch cutters. Journal of Manufacturing Science and Engineering 121 (1999) 173-178
16. Budak E. An analytical design method for milling cutter with nonconstant pitch to increase stability, part 2: application. Journal of Manufacturing Science and Engineering 125 (2003) 35-38
17. Olgac N., and Sipahi R. A unique methodology for chatter stability mapping in simultaneous machining. Journal of Manufacturing Science and Engineering 127 (2005) 791-800
18. Merdol S.D., and Altintas Y. Multi frequency solution of chatter stability for low immersion milling. Journal of Manufacturing Science and Engineering, Transactions of the ASME 126 (2004) 459-466
19. Hartung F., Insperger T., Stepan G., and Turi J. Approximate stability charts for milling processes using semi-discretization. Applied Mathematics and Computation 174 (2006) 51-73
20. Insperger T., and Stepan G. Updated semi-discretization method for periodic delay-differential equations with discrete delay. International Journal for Numerical Methods in Engineering 61 (2004) 117
21. Mann B.P., Bayly P.V., Davies M.A., and Halley J.E. Limit cycles, bifurcations, and accuracy of the milling process. Journal of Sound and Vibration 277 (2004) 31-48
22. Turner S., Merdol D., Altintas Y., and Ridgway K. Modelling of the stability of variable helix end mills. International Journal of Machine Tools and Manufacture 47 (2007) 1410
23. Patel B.R., Mann B.P., and Young K.A. Uncharted islands of chatter instability in milling. International Journal of Machine Tools & Manufacture 48 (2008) 124-134
24. Ogata. Discrete Time Control Systems (1995), Prentice-Hall, Englewood Cliffs, NJ
25. Altintas Y. Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design (2000), Cambridge University Press, Cambridge
26. Martellotti M.E. An analysis of the milling process. Transactions of ASME 63 (1941) 677-700
27. Martellotti M.E. An analysis of the milling process. Part II: down milling. Transactions of ASME 67 (1945) 233-251
28. Virgin L.N. Introduction to Experimental Nonlinear Dynamics: a Case Study in Mechanical Vibration (2000), Cambridge University Press, Cambridge
29. Mann B.P., Young K.A., Schmitz T.L., and Dilley D.D. Simultaneous stability and surface location error in milling. Journal of Manufacturing Science and Engineering 127 (2005) 446-453
30. Insperger T., and Stepan G. Stability analysis of turning with periodic spindle speed modulation via semidiscretization. Journal of Vibration and Control 10 (2004) 1835
31. Budak E., and Altintas Y. Analytical prediction of chatter stability in milling-part II: application of the general formulation to common milling systems. Journal of Dynamic Systems, Measurement and Control 120 (1998) 31-36
32. Reddy J.N. An Introduction to the Finite Element Method. second ed (1993), McGraw-Hill, New York
33. Zatarain M., Munoa J., Peigne G., and Insperger T. Analysis of the influence of mill helix angle on chatter stability. CIRP Annals-Manufacturing Technology 55 (2006) 365
34. Sims N. The self-excitation damping ratio: a chatter criterion for time-domain milling simulations. Journal of Manufacturing Science and Engineering 127 (2005) 433-445
35. Campomanes M.L., and Altintas Y. An improved time domain simulation for dynamic milling at small radial immersions. Journal of Manufacturing Science and Engineering 125 (2003) 416-422